OPERATOR’S MANUAL FOR AirVANTAGE™ TwoHAND™ GEARED … 3 in Two Hand 3000r… · TwoHAND™...

DOC 1908 1 Revision 12/19/11

OPERATOR’S MANUAL FOR AirVANTAGE™TwoHAND™ GEARED 3,000 RPM3 in. (77 mm) BUFFER/SANDER

Operator InstructionsIncludes – Please Read and Comply, Proper Use of Tool, Warranty, Product Configuration and Specifications Table, Parts Page, Parts List, Work Stations, Putting the Tool Into Service, Operating Instructions and Compressor Layout, Back-Up Pads, Service Tools and Accessories, Overhaul Service Kit, Spare Part Kits, Service Instructions.

Manufacturer/SupplierAirVANTAGE™ Tools10018 Lower Azusa Road; Unit #C;El Monte, California 91731 USA Tel: (626) -575-4568 Fax: (626)-575-4968

All AirVANTAGE™ 3 in. TwoHAND™ Geared Buffer/Sanders are warranted for defects in materials or workmanship for one year from the date of delivery to the user. Combined with the AirVANTAGE™ name, this Warranty expresses our total confidence in the superior quality, durability, and performance of the AirVANTAGE™ LP. To receive any expressed or implied warranty, tool must be repaired by an authorized AirVANTAGE™ Service Center. The “Service Instructions” section in this document is provided for use after completion of the warranty period. To receive war-ranty, tools must be operated under the conditions as described in the “Putting the Tools into Service” section of this document and be connected to an air supply system as shown in Figure 1. Tools that have been exposed to extreme conditions will be covered under warranty at the sole discretion of AirVANTAGE™.

AirVANTAGE™ Warranty

Please Read and Comply with:

Proper Use of Tool

1) General Industry Safety & Health Regulations, Part 1910, OSHA 2206, available from: Superintendent of Docu-ments; Government Printing Office; Washington DC 20402

2) Safety Code for Portable Air Tools, ANSI B186.1 available from: American National Standards Institute, Inc.; 1430 Broadway; New York, New York 10018

3) State and Local Regulations.

This Buffer/Sander is designed for sanding all types of materials i.e. metals, wood, stone, plastics, etc. using abrasive designed for this purpose. Do not use this buffer/sander for any other purpose than that specified without consulting the manufacturer or the manufacturer’s authorized supplier.

Do not use back-up pads that have a working speed less than 3,000 RPM free speed. Never use back-up pads that have a weight and/or size different than the machine was specifically designed for.

Required Personal Safety Equipment Safety Glasses Breathing Masks

Safety Gloves Ear Protection

Recommended Airline Size - Minimum

10 mm 3/8 in

Recommended Maximum Hose Length

8 meters 25 feet

Air PressureMaximum Working Pressure 6.2 bar 90 psigRecommended Minimum NA NA

Declaration of conformityAirVANTAGE™ Tools

10018 Lower Azusa Road, Unit #C; El Monte, California 91731 USAdeclare on our sole responsibility that the product

3 in. TwoHAND™ Geared Buffer/Sander (See “Product Configuration/Specifications” Table for particular Model) to which this declaration relates is in conformity with the following standard(s) or other normative document(s) EN ISO 15744:2008. Following the provisions of

89/392/EEC as amended by 91/368/EEC & 93/44/EEC 93/68/EEC Directives and consolidating Directive 2006/42/EC

Place and date of issue Name Signature or equivalent marking of authorized person

ImportantRead these instructions care-fully before installing, operating, servicing or repairing this tool. Keep these instructions in a safe accessible location.

12.19.2011, Taiwan Peter Wu

Original Instructions

DOC 1908 2 Revision 12/19/11

Parts Page

XPB01836019 mm x 1.5 mm O-RINGXPA0043597SCREW, BUTTON HEAD TORX M4.0 X 30 mm BLACKXPA1430581AirVANTAGE™ SIDE HANDLE

136.0 mm LH NV GREY HOUSING W/SIDE HANDLE HOLEXPC0221621INTERNAL RETAINING RINGXPA0039611TwoHAND™ SPEED CONTROL

RAG 08/14/08 PWH 08/18/08

-ITEM 57: XPA1926 WAS XPB0337DRAG 04/04/08 PWH 04/18/08

IN MANUAL SO THAT PARTS PAGE WOULD FIT-PARTS WERE NOT REARRANGED

C

RAG 02/06/08 PWH 03/11/08

INCREASED BY TWO NUMBERS 46, 55, 56, AND 58 WERE NOT-IN TORQUE SETTINGS TABLE ITEM

YTQNOITPIRCSEDN/PTI1YLBMESSA RECAPS ROTOM mm 0.027921APX11GNIR GNINIATER LANRETXE0400APX21SDLEIHS 2 - GNIRAEB 8 X 62 X 011200APX31ETALPDNE RAER7100BPX41ROTOR DENIHCAM5000BPX55ENAV0100APX61YEK FFURDOOW mm 31 x mm 31400APX71GNIR-O mm 0.2 x mm 52400APX81YLBMESSA REDNILYC5000APX91ETALPDNE TNORF6100BPX011SDLEIHS 2 - GNIRAEB 8 X 82 X 219100APX111ROTOM mm 0.02 DNAH 2 - YLBMESSA TFAHS ROTOM9921APX211RECAPS ROTOM mm 0.025921APX313RAEG TENALP2510APX413GNIRAEB ELDEEN 7 x 3 x 54220APX511RAEG GNIR1510APX611GNIR-O mm 1.3 x mm 4.935400APX711GNISUOH ELDNIPS DENIHCAM0600BPX811) B2-CNU 02-4/1 ( YLBMESSA ELDNIPS YRATENALP6540APX911SDLEIHS/SLAES ON - GNIRAEB 5 x 42 x 517410APX021KHT 01.0 x DO 5.32 x DI 0.02 ,RECAPS3120APX121LAES 1 - GNIRAEB 5 x 42 x 518410APX221GNIR GNINIATER mm 3.410110APX321GNIR GNINIATER7110APX422GULP DEDAERHT 8M1171APX52

26 XPB0383 36.0 mm RH NV PMS 422 GREY AirVANTAGE HOUSING W/SIDE HANDLE HOLE 1

1)senihcaM MPR 000,01 rof( TRESNI RELFFUM2300APX721LAES GNISUOH POT8121APX821LAES GNISUOH REWOL VN5521APX921GNIR EVITPAC TELNI0150APX031GNIR-O mm 87.1 x mm 6.79050APX132RELFFUM6770APX231GNIR-O mm 87.1 x mm 7.358260APX33

34 XPA0731 INLET/EXHAUST END CAP ASSEMBLY FOR NV MACHINES 14KCALB mm 51 X 0.4M XROT DAEH NOTTUB ,WERCS8931APX531YLBMESSA GNIHSUB TELNI TPN 81-4/13100APX631KCALB - REGNAH0240BPX732GNIR RECAPS5681APX83

39 XPB0356 36.0 mm DIE-CAST MACHINE MOTOR HOUSING W/SIDE HANDLE MOUNTING STUDS 1

1NIP GNIRPS REDNILYC4000APX041YLBMESSA METS EVLAV5560APX141EVEELS EVLAV5100APX241TAES EVLAV9000APX341EVLAV7000APX441GNIRPS EVLAV4100APX541YLBMESSA LAES ENILRIA0370APX64

47 XPA1859 AirVANTAGE™ 3,000 RPM BUFFER/SANDER LEVER - 2 HAND 11PMALC GNIBUT6150APX841GNIBUT TELNI1150APX941TEKSAG TSUAHXE0050APX051ELZZON TSUAHXE VC/VN2810BPX153WERCS PAC DAEH NOTTUB TEKCOS XEH 8 X 4M4660APX251GNIBUT TSUAHXE7150APX351DUORHS REFFUB8220CPX451HCNERW mm 315410APX55

56 N/A 1 Back-up Pad supplied with each tool (type determined by model) 157 XPA1926

REVISION RECORDR DESCRIPTION / DATE

A -RELEASE FOR PRODUCTION

RAG 12/17/07 PWH 12/21/07

B

-ITEMS 32 AND 33 WERE NOT ON-ITEMS 34 THRU 62 WERE NOT INCREASED BY TWO

ITEM NO. TORQUE SETTINGS in.-lbs (N-m)18 55 - 65 (6.2 - 7.3)35 27 - 30 (3.0 - 3.4)36 60 - 72 (6.8 - 8.1)52 21 - 30 (2.4 - 3.4)58 29 - 33 (3.3 - 3.7) RAG

X'POLE PRECISION

XPD0044P/N

TITLE

TOOLS INC.

0.5°NA

DRWN BY / DATE

MATERIAL

PROPRIETARY AND CONFIDENTIAL

PERMISSION OF X'POLE PRECISION TOOLS INC. IS PROHIBITED.

.XX +/-

DUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN

CKD BY / DATE

12/20/07

NA

PROPERTY OF X'POLE PRECISION TOOLS INC. ANY REPRO-

ANGLES +/-

0.10.05

NA

ENG APP / DATE

STD TOL

12/21/07

.X +/-

PWH

XX/XX +/-

THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE

.XXX +/-

AirVANTAGE™ 3 in. (77 mm), 3,000 RPM GEARED BUFFER/SANDER PARTS PAGE

2

3

4

9

8

10

11

12

14

15

16

17

18

19

20

21

22

23

24

7

5

1

26

29

42

41

40

43

44

45

46

52

51

50

39

54

55

56

32

30

49

48

53

35

35

59

62

60

61

6

13

31

33

34 35 36

28

57

58

25

27

25

47

38

37

58

58

58

DOC 1908 3 Revision 12/19/11

Parts ListItem Part No. Description Qty.

1 AVA1297 MOTOR SPACER ASSEMBLY 12 AVA0040 EXTERNAL RETAINING RING 13 AVA0021 BEARING - 2 SHIELDS 14 AVB0017 REAR ENDPLATE 15 AVB0005 ROTOR 16 AVA0010 VANE 57 AVA0041 WOODRUFF KEY 18 AVA0042 O-RING 19 AVA0005 CYLINDER ASSEMBLY 1

10 AVB0016 FRONT ENDPLATE 111 AVA0019 BEARING - 2 SHIELDS 112 AVA1299 MOTOR SHAFT ASSEMBLY 113 AVA1295 MOTOR SPACER 114 AVA0152 PLANET GEAR 315 AVA0224 NEEDLE BEARING 316 AVA0151 RING GEAR 117 AVA0045 O-RING 118 AVB0060 SPINDLE HOUSING 119 AVA0456 PLANETARY SPINDLE ASSEMBLY 120 AVA0147 BEARING - NO SEALS/SHIELDS 121 AVA0213 SPACER 0.10 THK 122 AVA0148 BEARING - 1 SEAL 123 AVA0110 RETAINING RING 124 AVA0117 RETAINING RING 125 AVA1711 THREADED PLUG 226 AVB0383 RH HOUSING 127 AVA0032 MUFFLER INSERT 128 AVA1218 TOP HOUSING SEAL 129 AVA1255 NV LOWER HOUSING SEAL 130 AVA0510 INLET CAPTIVE RING 131 AVA0509 O-RING 132 AVA0776 MUFFLER 233 AVA0628 O-RING 134 AVA0731 INLET/EXHAUST END CAP ASSEMBLY FOR NV MACHINES 135 AVA1398 SCREW 436 AVA0013 INLET BUSHING ASSEMBLY 137 AVB0420 HANGER OPT38 AVA1865 SPACER RING OPT39 AVB0356 MACHINE MOTOR HOUSING W/SIDE HANDLE MOUNTING STUDS 140 AVA0004 CYLINDER SPRING PIN 141 AVA0655 VALVE STEM ASSEMBLY 142 AVA0015 VALVE SLEEVE 143 AVA0009 VALVE SEAT 144 AVA0007 VALVE 145 AVA0014 VALVE SPRING 146 AVA0730 AIRLINE SEAL ASSEMBLY 147 AVA1859 LEVER 148 AVA0516 TUBING CLAMP 149 AVA0511 INLET TUBING 150 AVA0500 EXHAUST GASKET 151 AVB0182 NV/CV EXHAUST NOZZLE 152 AVA0664 SCREW 353 AVA0517 EXHAUST TUBING 154 AVC0228 BUFFER SHROUD 155 AVA0145 13 mm WRENCH 156 N/A 1 Back-up Pad supplied with each tool (type determined by model) 157 AVA1926 SIDE HANDLE OPT58 AVA1430 SCREW 759 AVA0043 O-RING 160 AVB0183 SPEED CONTROL 161 AVA0039 INTERNAL RETAINING RING 162 AVC0221 LH HOUSING 1

DOC 1908 4 Revision 12/19/11

Specifications subject to change without prior notice.*The values stated in the table are from laboratory testing in conformity with stated codes and standards and are not sufficient for risk evaluation. Values measured in a particular work place may be higher than the declared values. The actual exposure values and amount of risk or harm experienced to an individual is unique to each situation and depends upon the surrounding environment, the way in which the individual works, the particular material being worked, work station design as well as upon the exposure time and the physical condition of the user. AirVANTAGE™ cannot be held responsible for the consequences of using declared values instead of actual exposure values for any individual risk assessment.Further occupational health and safety information can be obtained from the following websites:http://europe.osha.eu.int (Europe)http://www.osha.gov (USA)

Product Configuration/Specifications:3,000 RPM 3 in. (77 mm)

Orbit Pad Face

Vacuum Type Pad Type Pad Size

in. (mm)Model

Number.

Product Net Weight

Pound (kg)

Heightin. (mm)

Lengthin. (mm)

PowerHP (watts)

AirConsumption scfm (LPM)

*Noise Level dBA

*Vibration Level m/s2

**Uncertainty Factor2

NA Hook Non-Vacuum Low Profile 3 (77) 032401 2.1 (0.96) 4.47

(113.6)9.68

(245.9) 0.46 (343) 21 (594) 85 1.2 0.6

*The noise test is carried out in accordance with EN ISO 15744:2008 - Hand-held non-electric power tools -- Noise measurement code -- Engineering method (grade 2).

**The vibration test is carried out in accordance with EN 28662-1 Hand-held portable power tools – Measurement of vibration at the handle. Part 1: General and EN 8662-8. 1997 Hand-held portable power tools – Measurement of vibration at the handle. Part 8: Polishers and rotary. orbital and random orbital sanders.

DOC 1908 5 Revision 12/19/11

AirVANTAGE™ Back-Up Pads,Polishing/Buffing Pads and

Compounds

Work Stations

Putting the Tool into Service

Operating Instructions1) Read all instructions before using this tool. All operators

must be fully trained in its use and aware of these safety rules. All service and repair must be carried out by trained personnel.

2) Make sure the tool is disconnected from the air supply. Select a suitable abrasive and secure it to the back-up pad. Be careful and center the abrasive on the back-up pad.

3) Always wear required safety equipment when using this tool.

4) When sanding always place the tool on the work then start the tool. Always remove the tool from the work before stopping. This will prevent gouging of the work due to excess speed of the abrasive.

5) Always remove the air supply to the buffer before fitting, adjusting or removing the abrasive or back-up pad.

6) Always adopt a firm footing and/or position and be aware of torque reaction developed by the buffer.

7) Use only correct spare parts.8) Always ensure that the material to be sanded is firmly

fixed to prevent its movement.9) Check hose and fittings regularly for wear. Do not carry

the tool by its hose; always be careful to prevent the tool from being started when carrying the tool with the air supply connected.

10) Do not exceed maximum recommended air pressure. Use safety equipment as recommended.

11) The tool is not electrically insulated. Do not use where

Use a clean lubricated air supply that will give a measured air pressure at the tool of 90 psig (6.2 bar) when the tool is running with the lever fully depressed. It is recommended to use an approved 3/8 in. (10 mm) x 25 ft (8 m) maximum length airline. It is recommended that the tool be connected to the air supply as shown in Figure 1.Do not connect the tool to the airline system without incorpo-rating an easy to reach and operate air shut off valve. The air supply should be lubricated. It is strongly recommended that an air filter, regulator and lubricator (FRL) be used as shown in Figure 1 as this will supply clean, lubricated air at the correct pressure to the tool. Details of such equipment can be obtained from your supplier. If such equipment is not used then the tool should be manually lubricatedTo manually lubricate the tool, disconnect the airline and put 2 to 3 drops of suitable pneumatic motor lubricating oil such as Fuji Kosan FK-20, Mobil ALMO 525 or Shell TORCULA® 32 into the hose end (inlet) of the machine. Reconnect tool to the air supply and run tool slowly for a few seconds to allow air to circulate the oil. If the tool is used frequently, lubricate it on a daily basis or lubricate it if the tool starts to slow or lose power.It is recommended that the air pressure at the tool be 90 PSI (6.2 Bar) while the tool is running so the maximum RPM is not exceeded. The tool can be run at lower pressures but should never be run higher than 90 PSI (6.2 Bar). If run at lower pres-sure the performance of the tool is reduced.

there is a possibility of coming into contact with live electricity, gas pipes, water pipes, etc. Check the area of operation before operation.

12) Take care to avoid entanglement with the moving parts of the tool with clothing, ties, hair, cleaning rags, etc. If entangled, it will cause the body to be pulled towards the work and moving parts of the machine and can be very dangerous.

13) Keep hands clear of the spinning pad during use.14) If the tool appears to malfunction, remove from use im-

mediately and arrange for service and repair.15) Do not allow the tool to free speed without taking precau-

tions to protect any persons or objects from the loss of the abrasive or pad.

Closed Loop Pipe SystemSloped in the direction

of air flowDrain Leg

Ball Valve

To Tool Station

Filter

Drain Valve

Regulator

Lubricator

BallValve

Ball Valve

Air Flow

Air Dryer

Air Compressorand Tank

Air HoseTo Couplerat or near Tool

Figure 1

The tool is intended to be operated as a hand held tool. It is always recommended that the tool be used when standing on a solid floor. It can be in any position but before any such use, the operator must be in a secure position having a firm grip and footing and be aware that the buffer can develop a torque reaction. See the section “Operating Instructions”.

AirVANTAGE™ back-up pads are perfectly mated for use on the AirVANTAGE™ LP. Constructed from premium, industrial-quality materials and featuring a riveted fiber-glass and steel hub with molded urethane, their durability and precise construction are the ideal complement to the performance of the AirVANTAGE™ LP. See “Product Configuration/Specifications” Table for the correct re-placement pad for a particular model.

Description Part #3 in. Low profile, non-vacuum, hook face 1232101

DOC 1908 6 Revision 12/19/11

AVB0425 Overhaul Service Kit for 3,000 RPM TwoHAND™ 3 in. Buffer/Sander ContentsPart No. Description Qty.AVA0040 External Retaining Ring 1AVA0042 O-Ring 1AVA0509 O-ring 1AVA0039 Internal Retaining Ring 1AVA0043 O-Ring 1AVA0009 Valve Seat 1AVA0007 Valve 1AVA0014 Valve Spring 1AVA0776 Muffler 2AVA0032 Muffler Insert 1AVA0730 Airline Seal Assembly 1AVA0628 O-ring 1AVA0148 Bearing – 1 Shield 1AVA0147 Bearing – No Shields 1AVA0021 Bearing – 2 Shields 1AVA0019 Bearing – 2 Shields 1AVB0005 Rotor 1AVA0010 Vanes 5AVA0224 Needle Bearing 3AVA0041 Key 1AVA0500 Exhaust Gasket 1AVA1908 3,000 RPM 3 in. TwoHAND™Sander/Buffer Service Instructions 1

AirVANTAGE™ Overhaul Service KitThe AVB0425 AirVANTAGE™ Overhaul Service Kit contains all the replacement parts that naturally wear over time and a straight-forward manual to make servicing an AirVANTAGE™ Buffer/Sander simple. Overhauling the Buffer/Sander can be made even easier with the use of the above Service Tools. The Service Tools also reduce the chance of improper assembly.

AirVANTAGE™ Service Tools and Accessories

When an AirVANTAGE™ TwoHAND™ Buffer/Sander needs to be serviced, we offer a tool kit to make the disassembly/assembly fast and easy. The Service Tools are highly recommended for use with the Overhaul Service Kit. NOTICE: To receive any ex-pressed or implied warranty, the tool must be repaired by an authorized AirVANTAGE™ Service Center. The 3 in. Buffer/Sanders Service Instructions section provided are for use after completion of the warranty period.

AVA1903 - 3 in. 3,000 RPM GEARED BUFFER SERVICE TOOL KIT

T-11 5/16 - 24 to1/4 x 20 SPINDLE

PULLER ASSEMBLY

T-10A & T-10B SPINDLEBEARING PRESS TOOL

AVA0486 - UNIVERSAL SERVICE TOOL KIT

T-6 MOTOR LOCK RING WRENCH/SPINDLE PULLER

T-7 SOFT COLLAR T-8 MOTOR FACE PLATE

BEARING REMOVAL TOOL T-13 BEARING PRESS TOOL

T-9 12 mm ID BEARING PULLER

T-1 ROS SPINDLE BEARING PRESS TOOLS

SERVICE INSTRUCTIONS FORAirVANTAGE™ 3,000 RPM TwoHAND™

3 in. (77 mm) BUFFER/SANDER

DOC 1908 7 Revision 12/19/11

Sander Spare Parts Kits

Air Inlet Kit Reorder P/N AVA1879

12,000 RPM Muffler KitReorder P/N AVA1877

Spindle Bearing KitReorder P/N AVA0715

Endplate Bearing KitReorder P/N AVA0614

Speed Valve KitReorder P/N AVA1880

Rotor, Vanes and Key KitReorder P/N AVA0709


A-RELEASE FOR PRODUCTION

RAG 01/31/08 PWH 02/13/08

B

-ITEM 1 - XPA0655 WAS NOT REMOVED-ALL ITEM NUMBERS DID NOT DECREASE BY ONE-DWG TITLE WAS "AirVANTAGE SPEED VALVE KIT - 2 HAND"

RAG 01/20/09 MDR 01/20/09

C-ITEM 1 WAS NOT UPDATED PER XPB0183 REV. F

RAG 03/13/09 PWH 03/13/09

IT P/N DESCRIPTION QTY1 XPB0183 TwoHAND™ SPEED CONTROL 12 XPA0043 9 mm x 1.5 mm O-RING 13 XPA0039 INTERNAL RETAINING RING 14 XPA1886 LABEL FOR AirVANTAGE SPEED VALVE KIT - 2 HAND 15 NA PE BAG 1

XPA1880P/N

TITLE

DRWN BY / DATE

MATERIAL

PROPRIETARY AND CONFIDENTIALTHE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE




CKD BY / DATE ENG APP / DATE

STD TOL

.X +/-

.XX +/-

.XXX +/-

XX/XX +/-

ANGLES +/-

0.1

0.05

NA

NA

0.5°

X'POLE PRECISIONTOOLS INC.

RAG01/31/08

PWH02/13/08

REVISED 12/19 /05

AirVANTAGE™ SPEED CONTROL KIT - TwoHAND

SEE BOM

Scaled 50%

DESCRIPTION / DATERREVISION RECORD

RAG 08/20/08 PWH 08/20/08

-DRAWING WAS NOT IN SOLIDWORKSA

1. SAME AS XPA0621 EXCEPT AS NOTEDNOTES:

YTQNOITPIRCSEDN/PTI1SDLEIHS/SLAES ON - GNIRAEB 5 x 42 x 517410APX11KHT 01.0 x DO 5.32 x DI 0.02 ,RECAPS3120APX21LAES 1 - GNIRAEB 5 x 42 x 518410APX31GNIR GNINIATER7110APX41GNIR GNINIATER mm 3.410110APX51GAB EPAN61LEBAL TES GNIRAEB ELDNIPS EGATNAVriA6170APX7

TOOLS INC.

XX/XX +/-

PRECISION

/05

AirVANTAGE™ SPINDLE BEARING SET

XPA0715P/N

NANASTD TOL

TITLE

DRWN BY / DATE

MATERIAL



.XX +/-


DRM08/02/04

PWH08/10/04


ANGLES +/-

0.10.05


.X +/-

X'POLE

0.5°


.XXX +/-

REVISED 12/19

SEE BOM


A -RELEASE FOR PRODUCTION

RAG 01/30/08 PWH 02/13/08

YTQNOITPIRCSEDN/PTI2RELFFUM6770APX11)senihcaM MPR 000,01 rof( TRESNI RELFFUM2300APX21TIK RELFFUM MPR 000,21 EGATNAVriA ROF LEBAL3881APX31GAB EPAN4

RAG01/30/08

PWH02/13/08

REVISED 12/19

- 2 HAND

XPA1877

TOOLS INC.

NA

0.05

P/N

TITLE

DRWN BY / DATE

MATERIAL

.XX +/-



NA0.5°

X'POLE PRECISION

/05


ANGLES +/-

0.1



STD TOL

.X +/- XX/XX +/-


.XXX +/-

AirVANTAGE™ 12,000 RPM MUFFLER KIT

SEE BOM

Scaled 50%

DOC 1908 8 Revision 12/19/11

DISASSEMBLY INSTRUCTIONS

Motor Disassembly:1. Remove the Pad with the 13 mm Wrench. Take the T-

6 Motor Lock Ring Wrench/Spindle Puller (Included in XPA0486 Kit) and engage it into the tabs of the Spin-dle Housing. Rotate the T-6 Motor Lock Ring Wrench/Spindle Puller counter-clockwise until it disengages the Spindle Housing from the Motor Housing. Carefully lift the Spindle Housing up, while at the same time watching to collect any of the three Needle Bearings or the three Planet Gears that may fall out. Remove any remaining Planet Gears and Needle Bearings and set them aside. Set the Spindle Housing assembly out-of-the-way.

2. Remove the Motor Spacer.3. Grasp the Motor Assembly by the exposed end of the

Motor Shaft and pull out the Motor Assembly from the Motor Housing and set it aside.

4. Remove the Motor Spacer that is in the bottom of the motor assembly bore.

5. Remove the O-Ring from the Cylinder. Remove the Re-taining Ring from the Motor Shaft.

6. Remove the Rear Endplate, Cylinder, Rotor and five Vanes. This may require gripping the Rear Endplate with a (XPA0416) Bearing Separator and lightly pressing the Motor Shaft through the Bearing and Rear Endplate. CAUTION: The Key will damage the Front Endplate if the Motor Shaft is pressed through without removing the Key first. Remove the Key then press off the Front Endplate.

7. Remove the Bearings from the Endplates using the T-8 Motor Faceplate Bearing Removal Tool (Included in XPA0486 Kit). The end of the tool with the larger diam-eter is for pressing the Bearing in the Front Endplate out and the smaller diameter end is for pressing the Bearing in the Rear Endplate out.

Spindle Housing Disassembly:1. Take the Spindle Housing and with a small, thin-tipped

flathead screwdriver pick-out the slotted end of the Re-taining Ring, then continue to peel-out the Retaining Ring all the way around until it is free from the groove in the Spindle Housing.

2. Screw the threaded end of the T-6 Motor Lock Ring Wrench/Spindle Puller into the Planetary Spindle un-til hand tight. NOTE: Make sure the Planet Gears and Needle Bearings have been removed and set aside.

3. Remove the Planetary Spindle assembly. To accomplish this, create moderately sharp outward blows to the Plan-etary Spindle, this can be done by taking the cylindrical part of the T-6 Motor Lock Ring Wrench (Included in XPA0486 Kit) and sliding it up the handle away from the

Planetary Shaft and hitting the washers and set screw at the opposite end of the handle.

4. The Ring Gear does not normally have to be removed. If it is determined that it needs to be replaced, press it out from the same side the Planetary Spindle Assembly is pressed in. Press it out by pressing on the part of the gear teeth that is exposed when looking in the bore from the Planetary Spindle side.

5. With a small, thin-tipped flathead screwdriver pick-out the slotted end of the Retaining Ring, then continue to peel-out the Retaining Ring all the way around until it is free from the Planetary Spindle.

6. Use a (XPA0416) Bearing Separator to remove the Bear-ing, Shim and Bearing from the Planetary Spindle.

Housing Disassembly:1. Unscrew the threaded Plug(s) and the Handle (if used)

from the Motor Housing.2. Remove the Hook and Spacer Ring. (if used)3. Remove the Retaining Ring. The Speed Control (with

O-Ring) will now pull straight out from the Motor Housing. Use an o-ring pick to remove the O-Ring from the Speed Control.

4. Use a T-20 Torx driver to unscrew all Screws.5. Remove the Housings.6. Remove the Muffler and Seals from the Housing.7. Remove the End Cap.8. Unscrew the Inlet Bushing from the End Cap. Remove

the Mufflers, Captive Ring, and the o-rings from the End Cap.

9. Remove the exhaust Tubing, Tubing Clamp, and inlet Tubing from the motor housing assembly. Separate the exhaust Tubing, Tubing Clamp, and inlet Tubing from each other.

10. Unscrew Screws from the motor housing assembly.11. Remove the NV/CV Exhaust Nozzle and the Gasket from

the motor housing assembly.12. Press out the Spring Pin from the Motor Housing and re-

move the Throttle Lever.13. Remove the Seal Assembly. This component can be-

come damaged during removal and will need to be re-placed if damaged.

14. Remove the Spring, Valve, Valve Seat, and the Valve Stem from the Motor Housing. Use an o-ring pick to re-move the o-ring from the Valve Stem.

15. Remove the Sleeve from the Motor Housing.16. Remove the Shroud from the Motor Housing.

3,000 RPM – TwoHAND™ 3 in. (77 mm)BUFFER/SANDERS SERVICE INSTRUCTIONS

NOTICE: To receive any expressed or implied warranty, tool must be repaired by an authorized service center. The following general service instructions provided are for use after completion of the warranty period.

DOC 1908 9 Revision 12/19/11

Press Tool Top

Press Tool Base

Bearing

Spindle

Bearing

Shim

ASSEMBLY INSTRUCTIONSNOTE: All assembling must be done with clean dry parts and all bearings are to be pressed in place by the correct tools and procedures as outlined by the bearing manufacturers.

Housing Assembly:1. Press the Sleeve flush to the top of the Motor Housing.2. Lightly grease the o-ring and place it in the groove of the

Valve Stem. Install the Valve Stem into the Sleeve.3. Install the Valve Seat, the Valve and the Spring. Press

the Seal Assembly into the Motor Housing.4. Install the Throttle Lever onto the Motor Housing with the

Spring Pin.5. Install the Shroud onto the Motor Housing.6. Install the NV/CV Exhaust Nozzle and the Gasket using

the Screws. Torque settings to be 21 - 30 in-lbs (2.4 - 3.4 N-m). Insert the exhaust Tubing and the inlet Tubing into the Tubing Clamp. Then insert the exhaust Tubing into the Exhaust Nozzle and insert the inlet Tubing into the Seal Assembly.

7. Install the two Mufflers, O-Ring, Captive Ring, and O-Ring into the End Cap. Lightly grease the o-rings before installation.

8. Coat the threads of the Bushing Assembly with 1 or 2 drops of Loctite™ 222 or equivalent non-permanent pipe thread sealant. Screw the Bushing Assembly into the in-let port on the End Cap until hand tight. Torque settings to be 60 - 72 in-lbs (6.8 - 8.1 N-m).

9. Insert the inlet Tubing into the End Cap.10. Install the Muffler and Seals into the Housing.11. Install the internal housing components into the right side

Housing. Then install the left side Housing.12. Install the Screws. Torque setting to be 27 - 30 in-lbs (3.0

- 3.4 N-m) for the 15 mm long Screw. Torque setting to be 29 - 33 in-lbs (3.3 - 3.7 N-m) for the 30 mm long Screw.

13. Lightly grease the O-Ring and place it in the groove on the Speed Control. Insert the Speed Control into the Mo-tor Housing in the full on position. Install the Retaining Ring. Caution: Make sure the Retaining Ring is com-pletely snapped into groove in the Motor Housing.

14. Install the Spacer Ring into the Hook. Secure the hook

by screwing in the Plugs and/or install the optional Side Handle.

Planetary Spindle Assembly and Bearing Press Tool In-structions:1. Place the T-10A Spindle Bearing Pressing Tool Base

(Included in XPA0546 Kit) onto a flat, clean surface of a small hand press or equivalent with the spindle pocket facing upward. Place the Spindle Assembly into the spin-dle pocket by using its three planetary gear shafts to align it with the three bores in the Pressing Tool Base.

2. Place the Bearing (no seals/shields) onto the Spindle shaft. NOTE: Make sure that both the inner and outer races of the Bearings are supported by the Bearing Press Tool when pressing them into place. Press the Bearing onto the shoulder of the Spindle using the T-10B Spindle Bearing Press Tool Top (Included in XPA0546 Kit) as shown in Figure 6.

3. Place the Shim over the Spindle shaft and onto the face of the Bearing making sure it is on center. Press the (two seals) Bearing down using the T-10B Spindle Bearing Press Tool Top (Included in XPA0546 Kit), being careful to make sure the Shim is still centered on the vertical axis of the Spindle shaft and Bearing. See Figure 7. Secure the Retaining Ring onto the end of the Planetary Spindle Assembly.

4. If the Ring Gear was removed, press it into the Machined Spindle Housing until it rests on the shoulder.

5. Lightly press the entire Planetary Spindle Assembly into the bore of the Machined Spindle Housing. Secure the Retaining Ring into the groove of the Machined Spindle Housing.

6. Place the three Needle Bearings onto the planetary shafts of the Planetary Spindle Assembly. Place the three Planet Gears onto the Needle Bearings. Set the finished assembly aside being careful to not let the Planetary Gears or Needle Bearings fall-out.

DOC 1908 10 Revision 12/19/11

Motor Assembly:1. Press fit a Bearing (2 shields) into the Front Endplate and

a Bearing (2 shields) into the Rear Endplate.2. Press the Front Endplate and Bearing Assembly into po-

sition on the Motor Shaft. Place the Key into the groove on the Motor Shaft. Place the Rotor onto the Motor Shaft.

3. Place the Cylinder over the Rotor with the short end of the spring pin engaging the blind hole in the Front End-plate. Oil the five Vanes with a quality pneumatic tool oil and place in the slots in the Rotor. NOTE: The spring pin must project .060 in. (1.5 mm) above the flanged side of the Cylinder. Lightly press fit the Rear Endplate over the Motor Shaft and secure with the Retaining Ring. CAU-TION: The Retaining Ring must be placed so that the middle and two ends of the hoop touch the Bearing first. Both raised center portions must be securely “snapped” into the groove in the Motor Shaft by pushing on the curved portions with a small screwdriver.

4. Lightly grease the O-Ring and place in the air inlet of the Cylinder Assembly.

5. Place the Motor Spacer in the Motor Housing. Make sure the spring pin engages the pocket in the Housing.

6. Lightly grease or oil the inside diameter of the Motor Housing, line up the spring pin with the marking on the Motor Housing and slide the Motor Assembly into the Housing. Make sure the spring pin engages the hole in the Motor Spacer.

7. Place the Motor Spacer into the Motor Housing.

8. Place the O-Ring in the groove of the Machined Spindle Housing.

9. Take the Planetary Gears of the Machined Spindle Hous-ing assembly and line them up, and partially engage them with the gear in the Motor Assembly. Carefully screw the Machined Spindle Housing into the Motor Housing with the T-6 Motor Lock Ring Wrench/Spindle Puller (See “Service Tools and Accessories”) until hand tight. Torque setting to be 55 - 65 in-lbs (6.2 - 7.3 N-m). NOTE: A simple technique to assure first thread engagement is to turn the lock ring counter clockwise with the service tool while applying light pressure. You will hear and feel a click when the lead thread of the lock ring drops into the lead thread of the housing.

Testing:Place 3 drops of quality pneumatic air tool oil directly into the motor inlet and connect to a 90 psig (6.2 bar) air supply. The tool should run between 2,500 and 3,500 RPM for 3,000 RPM machines when the air pressure is 90 psig (6.2 bar) at the inlet of the tool while the tool is running at free speed.

* LOCTITE® is a registered trademark of the Loctite Corp.

DOC 1908 11 Revision 12/19/11

Symptom Possible Cause Solution

Low Power and/or Low Free Speed

Insufficient Air PressureCheck air line pressure at the Inlet of the Sander while the tool is running at free speed. It must be 90 psig (6.2 Bar).

Clogged Muffler(s)

See the “Housing Disassembly” sec-tion for Muffler removal. The Muffler can be back flushed with a clean, suitable cleaning solution until all contaminates and obstructions have been removed. If the Muffler can not be properly cleaned then replace it. Replace Muffler Insert (See the “Housing Assembly” Section).

Plugged Inlet ScreenClean the Inlet Screen with a clean, suit-able cleaning solution. If Screen does not come clean replace it.

One or more Worn or Broken Vanes

Install a complete set of new Vanes (all vanes must be replaced for proper oper-ation). Coat all vanes with quality pneu-matic tool oil. See “Motor Disassembly” and “Motor Assembly”.

Internal air leakage in the Motor Housing indicated by higher than normal air con-sumption and lower than normal speed.

Check for proper Motor alignment and Lock Ring engagement. Check for dam-aged O-Ring in Lock Ring groove. Re-move Motor Assembly and Re-Install the Motor Assembly. See “Motor Disas-sembly” and “Motor Assembly”.

Motor Parts Worn Overhaul Motor. Contact authorizedService Center.

Worn or broken Spindle Bearings

Replace the worn or broken Bear-ings. See “Shaft Balancer and Spindle Disassembly” and “Spindle Bearings, AirSHIELD™ and Shaft Balancer As-sembly”.

Air leakage through the Speed Con-trol and/or Valve Stem.

Dirty, broken or bent Valve Spring, Valve or Valve Seat.

Disassemble, inspect and replace worn or damaged parts. See Steps 2 and 3 in “Housing Disassembly” and Steps 2 and 3 in “Housing Assembly”.

Vibration/Rough Operation

Incorrect Pad Only use Pad Sizes and Weights de-signed for the machine.

Addition of interface pad or other material

Only use abrasive and/or interface de-signed for the machine. Do not attach anything to the Sanders Pad face that was not specifically designed to be used with the Pad and Sander.

Improper lubrication or buildup of foreign debris.

Disassemble the Sander and clean in a suitable cleaning solution. Assemble the Sander.

Worn or broken Rear or Front Motor Bearing(s)

Replace the worn or broken Bearings. See “Motor Disassembly” and “Motor Assembly”.

Troubleshooting Guide

AirVANTAGE™ Tools10018 Lower Azusa Road; Unit #C;

El Monte, California 91731 USATel: (626)-575-4568Fax: (626)-575-4968

OPERATOR’S MANUAL FOR AirVANTAGE™ TwoHAND™ GEARED … 3 in Two Hand 3000r… · TwoHAND™...

Documents

Transcript of OPERATOR’S MANUAL FOR AirVANTAGE™ TwoHAND™ GEARED … 3 in Two Hand 3000r… · TwoHAND™...